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激光制造業(yè)亟需組建優(yōu)秀的激光加工團隊，大力普及激光加工技術(shù)，設(shè)立激光加工教學(xué)、科研和生產(chǎn)基地，加大相關(guān)技術(shù)同步研究，將機器人技術(shù)、仿真技術(shù)應(yīng)用等大規(guī)模地應(yīng)用到城市軌道車輛制造中，發(fā)展我國自主特色的激光加工設(shè)備以及加工工藝。激光加工技術(shù)在城市軌道車輛制造中的應(yīng)用，包括焊接、切割、表面改性、打標、快速成型、打孔及微細加工等。文章以城市軌道車輛為研究對象，闡述了先進激光焊接、激光切割在城市軌道車輛制造和輪軌表面處理等的原理和特點，分析了目前激光加工技術(shù)在城市軌道車輛制造中的特點和應(yīng)用前景，為縮短與國外先進技術(shù)的差距，加快軌道交通技術(shù)儲備提供參考。

城市軌道交通已成為現(xiàn)代城市公共交通的主動脈，具有運量大、能耗低、效率高、污染小、準點率高等優(yōu)勢。中國如今已成為全球城市軌道交通建設(shè)投入的主力軍，甚至連許多二線城市都具備了軌道交通建設(shè)的條件與需求。
隨著中國政府“十三五”規(guī)劃的提出，國家發(fā)改委已批復(fù)了多地軌道交通的規(guī)劃，到2020年投資預(yù)計將超萬億。目前城市軌道車輛制造行業(yè)中，激光加工制造技術(shù)備受矚目，其很大程度上提升了城市軌道車輛制造水平；輕量化與高速化的趨勢，也持續(xù)為其提出新方向、新課題。

由于中國的城市軌道交通起步較晚，因此為了縮短與國外先進技術(shù)的差距，應(yīng)引進、研究和消化當(dāng)前最新技術(shù)及設(shè)計思路，加快軌道交通技術(shù)儲備，探究激光加工技術(shù)在城市軌道車輛制造中的應(yīng)用。車輛激光焊接車輛轉(zhuǎn)向架以及車體是城市軌道車輛上的關(guān)鍵構(gòu)成，材質(zhì)也經(jīng)歷了普通合金鋼、不銹鋼、鋁合金型材幾個階段。目前在城市軌道車輛制造中，逐步引入了激光焊接等新的加工工藝。

激光拼焊

激光拼焊是城市軌道車輛中最被看好的技術(shù)之一，屬于無接觸焊接，可將不同鋼種、厚度、表面處理的鋼板焊接成一個整體，區(qū)別于電阻滾壓縫焊，通過自由組合，使得構(gòu)件變輕，零件變少，不僅提高可靠性，為寬體車制造奠定基礎(chǔ)，同時也改善了焊接質(zhì)量，提高了鋼材收得率，并降低了生產(chǎn)成本。

激光組焊

激光組焊在城市軌道車輛車身制造中舉足輕重，通過雙件組焊、多件組焊，將已切割成形的各類車身構(gòu)件，焊接成白車身分總成，進而總裝成整車車身。激光組焊因其焊接強度高，可明顯改善車身強度、剛度及密閉性。焊接同時結(jié)合面小、變形小、焊接速度快、可焊材料范圍廣，適合于柔性化生產(chǎn)，投資效益好。但激光組焊技術(shù)也有明顯的缺點，如對夾具、被焊件、監(jiān)測精度等要求嚴格，焊接后檢測評價和返修困難，一次性投入大等。

激光-電弧復(fù)合焊

1) 不銹鋼車體制造。城市軌道車輛車體通常選用不銹鋼車體，由于電弧焊接后熱影響及變形等較嚴重，因此為改善外觀，過去常常進行涂裝作業(yè)，而現(xiàn)在則選用激光或電阻焊進行作業(yè)。

通過長期加工技術(shù)應(yīng)用的實踐、積累及分析，不銹鋼接頭焊接技術(shù)規(guī)范、疲勞曲線、硬度、抗拉強度、屈服強度、等技術(shù)指標相繼被取得或檢驗，車體激光焊接樣件的制評亦完成。


2) 車輛轉(zhuǎn)向架制造。城市軌道車輛轉(zhuǎn)向架通常選用日本進口或國產(chǎn)的中厚合金鋼板材，同時多選用熔化極氣體保護焊。用于長直縫焊接的機械人手臂，已被各廠商所引進，來改善焊接穩(wěn)定性；而開具有不同規(guī)格的坡口，通常留較小鈍邊，以確保熔透。激光-電弧復(fù)合焊優(yōu)化焊接效率，顯示了激光和電弧的特點；同時減少了設(shè)備和人員投入，降低了焊接成本，并且可選較大鈍邊。


車輛激光切割

激光切割技術(shù)特性城市軌道車輛制造廠商已大量使用激光切割技術(shù)，其加工的產(chǎn)品有很多，如車體、內(nèi)裝板材、轉(zhuǎn)向架，常選用二維平面切割。激光可以加工出高精度、高切割斷面質(zhì)量的零件外形、輪廓和孔。

固體(或CO2)激光切割機通常適用于碳合金鋼、不銹鋼，同時也適用于鋁合金板，可達到理想斷面加工質(zhì)量和切割速度。以某企業(yè)為例，軌道車輛車體為不銹鋼，選用6 k W激光和剪板機對6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機對14 mm以下板材進行下料，其材料為Q345C低合金結(jié)構(gòu)鋼。

下料環(huán)節(jié)激光切割

城市地鐵機車制造首先要準備相關(guān)材料，這個階段激光切割技術(shù)尤為重要。激光切割與火焰切割相比，切割速度快、工件變形小、加工精度高、適用性強、節(jié)料省錢、經(jīng)濟適用[16]，因此激光切割技術(shù)已被廣泛用于軌道車輛制造中。以某企業(yè)為例，其高速動車組車體選用激光和剪板機對6 mm以下板材下料，材料為鋁合金板材及型材。車輛轉(zhuǎn)向架選用6 k W激光切割機對12 mm以下板材下料[17]。

 

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MSC-FRQ-C Obsolete - 1KHz in / 4-20 mA out

PSPC-DC25/EL Prof Shop Floor SPC DC 25 User w/ eSig

PXI-8433/4

AS5USA-20411-VM-E

PFC375-3004S111

CONTEC PIO-16/16L（PCI）

AMPU61 2N8C3102-A

60-001-9004S

1492-N1 TERM BLCK Breakaway MTG Rail

通訊處理器CP 6ES7 341-1CH01-0AE0 CP341，標準串行通訊模塊，RS422/485 接口，最高 76.8kbit/s,15 針 D 型接口,可加載 ModbusRTU及 DataHighway 驅(qū)動

行程開關(guān) 3SE53221SB21

TIA 博途 WinCC 選件 6AV2107-0CA00-0BB0 SIMATIC WinCC Sm@rtServer for Runtime Advanced

1585J-M8HBJM-0M4 RJ45 Ethernet Media

1756-TBS6H ControlLogix 36 Pin Spring TRM Block

188-K1D500-N Miniature Circuit Breaker 50 A

194E-Y40M-1753-6N 40 A 194E Load switch

2090-CHBIFS8-12AA03 Kinetix 6000M IPIM Hybrid Cable

2090-UXNPBMP-10S15 MP-Series 15 m Length Power Cable

BC647MBP001 Machine Edition Professional Development Suite with Proficy GlobalCare Complete and USB Hardware key

GC647IFPRDV00150 GCC iFIX Profsnl SCADA 150 I/O Dev

IC200CHS002 I/O carrier box style

IC646MPTS99 GE Compare Unlimited Seat Site License

IC647IFSTDV00150C iFIX Standard HMI 150 I/O Development (M1Component Part)

IC670ALG320 Analog Output, Current/Voltage, 4 Channel, Grouped

IC697CPU788RR CPU, 100 Triplex (voted) I/O, GMR Redundancy

IC800S2KDEM1 S2K encoder-based case demo with 4.3 amp Devicenet controller and Motorcube

ControlLogix/1756 System 1756-OX8I N.O./N.C. ISOLATED RELAY OUTPUT 8 PTS (36 PIN)

Industrial Computers 6182H-10KRH6D VVCE 1000, KEYPAD, STD MEM, RIO/DH, DC

Process Control 1757-FIMUL010 FOUNDATION FIELDBUS FIM MODULE USAGE LICENSE

Operator Interface 2711P-RDK12C PV PLUS 1250, KEYPAD DISPLAY MODULE

Support 9355-WABENR SUPT REINSTATEMENT CONTRACT FOR 9355WABEN

Support 9351-WESS SUPT RENEWAL CONTRACT FOR 9351WES

ControlNet Products 1756-CNBR CONTROLNET REDUNDANT BRIDGE MODULE

RSI Software Products 9301-2SE2400ITU2 RSVIEW32 WORKS 300-32K UPGRADE IN-SUPT (IT)

RSI Software Products 9355-WABOEMITE RSLINX OEM - ITALIAN

Motion Control MPL-A320P-HK22AA MOTOR,SERVO,2.94NM,5000RPM,ENCDR,230V,4.0KG

Motion Control 2090-U3AE-D4430 CABLE,TWO AXISTO LOGIX 1756MOAE2 CARD,30M

CBL-120 CABLE. ALLEN-BRADLEY SLC100/150 PROG. PORT (RS-422)

IC600CP612RR 13" Series Six Plus CPU 24Vdc Power Supply (8 Slots)

IC800S2K4DSTRKIT S2K Series Controller Starter Kit, 4.3 Amp with DeviceNet

OC647IFESGDV00900C iFIX Optn: ESig & ERec 900 I/O Development (M1Component Part)

PCMCIA-232

946-F-23463D